Manual Decoiler Machine

 

Decoiler meaning:

 

A material handling machine located at the beginning of a production line. decoiler used to hold and safely pay off or uncoil the steel strip. Coiler controls the speed and direction of the strip of metal and is sent to the line for processing, such as slitting or tube mill entry also roll forming entry. Decoiling is the action of unwinding a parent coil, making it flat and cutting it into sheets.

 

decoiler for sale

decoiler for sale

 

Decoiler machine design

actually, there is a sensor between decoiler and roll forming machine. If the coil is tight, the sensor will let the uncoiler go forward. If the coil is loose, the sensor will let the uncoiler stop. in fact, LOTOS is specialized in providing custom-built Manual Decoiler to our customers. De-Coiler offered by us finds application as an accessory machine that is used as support for expanded metal mesh machine.

de_coiler or uncoiler use in all roll forming machine such as:

 

 

manual sheet metal decoiler

manual sheet metal decoiler

 

 

 

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PU-foamed rolling shutter roll forming machine
(4.8)

Roll Forming Operation Manual

 

How to adjust a roll former ??

LOTOSFORMING guides and explains many of the common issues encountered in the roll forming process and roll forming operation manual, all factors that contribute to possible problems such as material, design, and manufacture.

roll forming operation manual is a process that developed by gradually bending the metal through a series of roll stands, or passes. Each stand must produce the appropriate amount of deformation for which it was designed. when roll-forming problems occur. it is important to examine each stage of the process and not merely the stand at which the problem initially appears. The goal of a roll forming operation achieves when there is uniform metal deformation throughout the line. Roll forming operation manual design to be reasonable during the operation. If run “popping” throughout the operation, the operation needs to be investigated.

Two basic types of roll forming systems utilize a pre-cut line and a post-cut line. A pre-cut line snips the incoming material to a specific length prior to roll forming operation manual. During post cut line operation, the roll-formed panel runs continuously and shear to the required length after roll forming.

 

roll former

roll-former

 

Roll forming operation :

MATERIAL

One of the main parameters that define the success of a roll forming operation is the character of the material. for design the optimal process, the designer should provide material information to use prior to the tooling designing such as material mechanical property ranges, gauge tolerances and shape tolerances, different metallic coatings.

 

ALIGNMENT

Mill alignment is critical. forming rolls and their components must align with each other both horizontally and vertically. The rolls must align both side-to-side and pass-to-pass. Forming material with the gauge either lighter or heavier than that for which the tooling is designed can result in problems. Using material thinner than the designed gauge can lead to finish radii greater than the intended design. This is usually offset by over-tightening the rolls, which causes a decline in tool life.

 Processing heavier gauge material than intended can also lead to larger radii than designed. When running thicker material, the tooling will make contact on the side of the tool radii leaving no center contact with the tooling. Since the material is not in proper contact with the tooling, gap differences from side to side become more critical. Small side-to-side roll gap differences can result in a twist, bow or sweep problems.

 

SETUP

setup by the roll tooling manufacturer, feeler or wire gauges are most often used to set the gaps on roll-forming stands. This should ideally be done each time the metal being utilized changes significantly in gauge. Operators must be sure to periodically check for tooling wear or machine wear.

Each stand consists of top and bottom rolls designed to provide the necessary part dimensions. position of the top roll can be adjusted via screws to change the gap between rolls, thereby changing the forming pressure applied to the metal at each stand. The final roll gap adjustment on each stand should always be down to compensate for the gear and bearing tolerances inherent to each stand.

 

CUT-OFF

Cutoff dies or shears are available in many types and variations. The most common types utilized for roll forming machines are the “slugless crop die” and the “flying shear”, or “cutoff die”.cutoff operation accurately cuts the part to the desired length in a manner that is essential to the continuous operation of the line. Slugless crop dies generally have a short stroke length, possess contoured blades, and rapidly cut-off the finished part. Since the cut-off action is extremely fast, an accurate cut can normally be performed without interruption to the continuous operation of the line. Proper set-up in this type of operation is critical.

 

Roll forming machine design

Line speeds, die speeds and die clearances must closely establish and monitor to prevent blade drag. This condition can result in panel buckling. Removal of the buckled panel from the line is time-consuming and may result in damage to the cutoff die, or in extreme cases, to the roll tooling. Even if the part does not buckle to the point that it jams the line, improperly timed cutting can cause problems upstream in the roll former.

Momentary interruptions in the later roll-forming stand, while the initial stands are still driving the material, can result in a wide variety of problems and/or imperfections. Minor buckling in the intermediate stands can result in oil canning type imperfections as well as other twist or dimensional issues in the finished panel. If the line is set-up with extremely loose tooling clearances. the effect of momentary line interruption from the cutoff operation may be seen all the way to the uncoiler. In this instance, the alignment of the entire line becomes integral to the cut-off operation. For example, if the uncoiler is out of alignment, the momentary line interruption could pull the material in a skewed manner from the uncoiler and potentially cause oil canning, twist or sweep problems.

Roll forming stands

A flying shear, or cut-off die, may require an increase in the line speed or panel height configuration. This allows the shear or die to attain the speed of the line prior to the cutoff operation. The timing of the shear is critical in this operation. Momentary interruptions in the latter roll-forming stands, as described above, will generally be larger in magnitude and more serious in nature as the speed of the cut-off operation increases. blade or die should always cut to an approved part. Improperly design/machine tools must avoid because they result in tight clearances, induce blade drag, tool drag, or lose clearances, which result in burrs on the finished panel.

 

roll forming machine price

roll forming machine price

 

Roll forming machine configuration :

With a working knowledge of the roll forming machine configuration and the roll former setup procedures, the root cause of many problems can determine at the plant level. Generally, the most important factor to keep in mind is that roll-forming issues must approach from a systematic point of view. That is, everything must consider from the incoming material properties, lubrication, roll former setup, uncoiler, and cut-off methods to the inspection details of the finished product. All or any of these factors can impact the acceptance of the finished part.

 

Important questions about adjusting the roll forming machine :

What are the Tool Gap Settings?

Gaps should initially be set at the material gauge with final adjustments made to achieve the desired final dimensions.

 

Does It Hold Dimension?

Ensure that the material within the order width and property tolerances. Check the gaps in the overbend stands for proper gauging.

Where Does the Imperfection Appear?

Inspect and check the tooling and gap settings where the imperfection occurs and in the stands upstream. Adjust to appropriate settings.

 

Are There Tight or Loose Areas on the Finished Panel Radii?

These imperfections typically denote improper tooling adjustment or worn tooling or bearings. Ensure that the tooling has proper gap settings. Inspect the tooling for worn areas. Inspect the line during operation for bearings with excessive movement. Occasionally, a worn bearing will make noise during operation. If bearing wears isolate and is consistently in one stand, it would be prudent to inspect the tooling in the entire line for alignment, wear and proper gap settings.

 

Do the Radius Lines Appear to Wander Down the Length of the Panel?

 Dry material, worn tooling, and improper tool alignment can cause this problem.

Roll Forming Systems :

Does the Tooling Run Eccentrically or Wander with Respect to Other Stands?

This is an indication of bent shafts, worn bearings, worn or misaligned tooling. If the tooling visually wanders from side to side, either the bearings are worn or the shaft locknut has come loose, or a shim has worn or fallen out. When the tooling is running in an elliptical pattern (egg shape, or up and down) the shaft itself may be bent. This will require checking the shaft for run-out with a dial indicator for the amount of movement.

 

Are There Areas Where Excessive Material Has Been Stripped Off During Forming?

This normally indicates dry material, tight clearances or improper tooling setup. Tooling stands where material slivers and/or debris accumulate should closely monitor, as this can lead to premature wear and finish panel imperfections. Material run with insufficient lubrication (dry areas) will run with increased friction in these areas during forming. This can cause the material to scrape during the roll-forming process, especially on the panel edges. In some cases, running dry material can raise the temperature of the tooling sufficiently to reduce the die clearances from heat expansion.

Tooling that gape to less than the material being formed, or tooling that is out of alignment from stand to stand can also cause this problem. Although it is sometimes not possible to prevent material debris accumulation on some stands. tooling should gape and check for alignment frequently.

Portable roll forming machine

Does the Material Track Properly into and from the Line?

Material that has differential lubrication edge-to-edge, the material with significantly different thickness edge-to-edge or tooling that is out of adjustment can cause tracking issues.

 

Does the Imperfection Appear at One Stand?

If this is the case, ensure the tooling gape properly at both the imperfection stand and also at the stands prior to where the imperfection occurs.

 

Does the Cut-Off Operation Run Transparent to the Line?

Drag or an out-of-time cut-off operation can induce a variety of imperfections or problems. In a post-forming cut-off process, the cut-off should not alter the continuous forming of the panel. Dull cut-off dies or knives can impart sufficient drag in the cut-off operation so that the formed panel actually begins to buckle in the cut-off operation. A similar condition is possible if a flying shear is out-of-time with the speed of the forming operation. Both of these conditions should address when they first appear, as permitting them to continue will eventually cause the panel to buckle in the line prior to the cut-off.

 

Does the Material Pop, Crackle, or Wrinkle at One Stand?

This is often the result of either tooling misalignment of the material entering the rolls in a skewed fashion. Roll-forming should approach from a systematic point of view. each stand design to perform a specific amount of forming.

 

Roll forming machine for sale

Successful roll-forming relies on a combination of factors, including material properties, tooling set-up, and roll former operation. As problems arise, it may be difficult to ascertain which factor is negatively impacting the finished panel to the point of rejection. This is why it is imperative to view the roll-forming process from a systematic point of view. With this approach, it is possible to determine the root cause of the problem and take the appropriate corrective course of action.

roll forming machine for sale

roll forming machine for sale

You can find all the information about the following :

  1. Shaft and roller design

  2. installation for roll forming machine
  3. How to design shaft and roller for roll forming machine
  4. Complete video for roll forming down roller adjustment
  5. Complete video for roll forming base setting
  6. How to fix roller position on the roll forming machine
  7. How to adjust roller on the roll forming machine
  8. How to adjust the roll forming machine
  9. Advanced roll forming
  10. Custom Roll Forming Process
  11. Roller Die
  12. roll forming roller material
  13. roll forming roller design
  14. roll forming basics
  15. roll forming process
  16. small roll forming machine
  17. roll-forming dies
  18. sheet metal roll forming machines
  19. roller materials
  20. how to adjust a roll former
  21. roll forming operation manual

 

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PU-foamed rolling shutter roll forming machine
(4.8)

Roll-up Shutter Door

In the previous generations, most shops and garages were closed by handmade steel bar doors or corrugated sheet doors. After ROLL FORMING MACHINE comes up to produce door shutter, all doors are changed to shutter slats. It has so many advantages from old-style doors. That here, we explain some good point of Roll-up Shutter Door.

China Supplier Roller Shutter Door Roll Forming Machine

Roller Shutter Door

Shutter Door Repairs

  • shutter door producing is more fast and easy by shutter roll forming machine; with any rolling shutter door details, shutter roll forming machine can produce within 10 minutes.
  • Installation for metal shutter door is faster and easy than old doors. Shutter and shutter joined together, and make various height for any Garage Shutter Doors.
  • For using: open and closed doors, it’s so fast and convinces with roll-up shutter door with tubular motor;
  • Shutter Door Repairs just check the shutter one by one, only need to change the damaged shutter, not necessary for whole doors replacement.

  • Not limited with listed advantages, but more benefit will be discovered during daily usage of ROLLING SHUTTER DOORS.

 

Rolling Shutter Slats Roll Forming Machine

Rolling Shutter Slats

 

Different types of Door Shutters:

In LOTOSFORMING MANUFACTURE, we mostly do door shutter design based on customer’s requirement, and shutter joint safety standard. But here, we wanna explain some global well-recognized door shutters:

  • Perforated Roller Shutter: it’s applied punch before forming step;
  • PolyurethaneFoamed Door Shutter: it’s applied PU Foam inside of shutter, it’s good for Fire-Proof and Sound-Proof. Less noise during rolling up and down;
  • Single Layer Rolling Shutter Door: in different door shutter design, such as shutter width and shutter section drawing.
Window shutter roll forming machine

Window shutter

 

Roller Shutter Doors producing:

All steel roller shutter is produced by Shutter Door Roll Forming Machine. In LOTOSFORMING, we use several types of rolling shutter machines based on shutter drawing.

  • Chain Transmission Rolling Shutter Machine;
  • Gearbox Transmission PU FOAMED Door Shutter Roll Forming Machine.

Up to Door Shutter Design, LOTOSFORMING engineers design proper rollers and forming steps according to shutter design.

 

roll forming machine door shutter

door shutter

 

Roller Shutter Doors Manufactures

should have a long history on design and produce rolling shutter machines to satisfy the standard requirement for final Foamed Shutters.

LOTOSFORMING ROLL FORMING Machine Manufacture has more than 50-year remarkable experience on Rolling Shutter Making Machine

Shutter Patti Machine is including decoiler, forming stations, hydraulic cutting unit, and PLC control system, and finished output table.

For Rolling Shutter Raw Material, different material could be applied, such as aluminum, galvanized(GI), color coated steel (PPGI) and PVC coated steel, and stainless steel (S.S) and so on.

 

Mostly, Shutter Door Roll Forming Machine, LOTOSFORMING install lubrication oil feeding device on the roll forming machine input, to mop the material with rollers to protect shutters material coated surface.

For any further question and inquiry, for shutter roll forming machine design and proposal, you may feel free to contract with LOTOSFORMING Roll Forming Machine Manufacturer.

 

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production line of stainless steel clad tube mill

Rolling mill for tube and square profile :

welded pipe and square forming machine

 

Here is a proposal for welded pipe or square profile also called tube mill production line. Tube mill production line as you can see from name included several different parts and machine to become a complete line.

what is tube mill

tube mill production line

1-Decoiler: Tube mill line will start from Decoiler, to open steel coil to a sheet for forming and processing. uncoiler or Decoiler has several different types: HYDRAULIC or MANUAL or MECHANICAL or SINGLE SIDE or DOUBLE SIDE, AND SO ON SO MOSTLY LOTOSFORMING uses double side hydraulic uncoiler for tube mill production line.

 

welded tube mill

double head hydraulic uncoiler

 

Tube manufacturing processes for seamless and welded tubes

2- shearing and butt welding machine: after decoiling steel coil mostly line has shearing and butt welding machine. its simple and small machine for shears the end of steel strips and welded both sides of steel strips to make tube mill line continuously. Also, some line does shearing and welding without a machine, with simple welding tools.

 

 

shearing and butt welding machine

shearing and butt welding machine

 

3- steel raw material accumulator: its mostly use for storage steel strips before forming because forming speed and working is not same all times and raw material should have stable feeding for continues welding and processing. Tube mill line accumulating from LOTOS has 2 different styles.

horizontal accumulator

horizontal accumulator

A: horizontal round material accumulating that has 2 AC motor, one for feeding steel strips from decoiler and secondary for driving accumulating, estimate OD of this part of tube mill line is 5 meter.

vertical accumulator

vertical accumulator

B: Vertical material accumulator it also has 2 AC motor, one for feeding raw material from decoiler to accumulator and another one for driving material accumulator. Selecting accumulator is based on customer producing area and budget.

 

Stainless Steel Pipe Making Machine

4- forming stations: this part of tube mill line is similar with Roll forming machines, but except horizontal shaft and roller it also forms material by vertical roller, to make tube shape and ready for welding. LOTOSFORMING mostly use 7-10 stations drive by heavy gears for forming.

 

forming stations

forming stations

 

5- pre-welding Guide and squeeze roller: this station is really important to make straight steel pipe seam for welding. this part makes sure pipe seem to inter to welding position flatly and squeeze roller make pressure both side of the tube to ensure the seam gap.

guide and scraper

guide and scraper

 

6- high-frequency welding: as you know this kind of welding is without electrode by high-frequency welding HF WELDER has several types by power LOTOS FORMING USE 200-400 ampere. this part of tube mill line includes serval different parts, such as Overall control table, Speed adjustor, Rectifier cabinet, Inverter output cabinet, Water-water cooling device (air-water cooling device) and so on plz refer to figure for all parts.

high frequency welding accessories

high-frequency welding accessories

squeeze roll and welding induction coil

squeeze roll and welding induction coil

 

 

7- scraper tools: to scrap welded seam, we can also scrap inside and outside of the tube to have a smooth surface for welded tubes.

8: Zinc spraying machine: this is optional for customers, but for making galvanized tube mill by galvanized steel we add zinc spraying machine after HF welding to coat the welding seam by Zinc spray. This machine uses zinc wire diameter 1.5-3 mm to MELT and spray zinc on the welded seam.

 zinc spraying machine

zinc spraying machine

 

Tube making process

10- Sizing stations: formed pipe after welding come to sizing stations to control size accuracy. Also for making the square profile in this station, we form welded pipe to various square profile. all horizontal and vertical roll stand drives by Spiral bevel gear, by a separate 40Cr shaft.

sizing stations

sizing stations

 

11- final straightening: these 2 stations straight pipe or profile by Turk’s head type, and 360°rotary after sizing to reach the required straightness before cutting.

 

rolling mill

rolling mill

 

12: CNC controlled cold cutting saw: by tube mill forming speed near 70 meters per minute we definitely need flying the cutting saw to reach back point on this speed. LOTOSFORMING has 2 types of the cutting saw: one is normal another is a cold cutting unit.

Cold cutting unit advantages it makes a finished profile without burr, to has the best accuracy and less cutting noise some industry required cold cutting saw.

cold cutting unit for tube mill production line

cold cutting unit for tube mill production line

 

13: run out table and packing system: finally after all processing to make steel tube or steel square profile we go to pack products for storage and shipping. LOTOS FORMING has several different packing systems for tube mills line, it’s up to customer requirement. here you can see the picture of automatic run out table and packing unit for square profiles.

 

automatic packing system for tube mill lines

automatic packing system for tube mill lines

 

 

 

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metal slitting machine line

what factors produced BURR in steel slitting?

Burr formation in Rotary steel slitting:

Rotary steel slitting is now widely used for distributing a wide strip into a some of the narrow strips or for modification wide sheet metal stock. However, with a conventional slitting process, burr formation on the slit edge is inevitable.

Burr formation is a common sheet metal defect and Burr control / deburring is an important issue for industrialist and engineers. It is produced in all shearing & cutting operations. In sheet metal parts burr is usual but after a specified limit, it takes a form of defect. This leads to rework and the quality problem of a part. So controlling this defect is the issue of quality as well.

This post describes what are the possible causes & how can we prevent it. Except die & punch clearances, there are still many factors which affect the burr formation.

As all the sheet metal industries are heavily affected by the burr problem, indicating the study of all the possible causes and remedies. This paper also clears that what practices can increase the tool life & how long we produce “burr-free” parts. It includes the selection of the best materials and methods for „press tools‟, „tool

BURR IN STEEL SLITTING

BURR IN STEEL SLITTING

Study of all factors causing BURR

Sheet metal parts play an important role in the automotive industry. Different types of reinforcement, body parts, and door parts are manufactured in sheet metal scope. With every manufacturing process, there are some defects associated with the same. In the same manner in sheet metal components there are also many types of defects arises in different processes. But out of these defects, the most common and prominent defect is a burr. This defect has no.of cost-effective impacts as follows.

  1. Adding unnecessary processes i.e. rework
  2. Production loss
  3. Quality issues
  4. Risk of a defect being passed to “customer”
  5. Affecting 5-S

Application of sheet metal components includes Aircraft industry, Automobiles, Construction work and many other applications such as appliances.

Causes of Defects Burr In Sheet Metal

Identify Cause  /Reason  /Countermeasure

Identify Cause: Operator awareness

Reason: The operator is not locating the part in specified location gauge. Feeding of double

parts/sheets which can damage the sharp edge of die and punch. This leads to burr formation.

Countermeasure: Training has to be provided

Identify Cause: Skill of Operator

Reason: The operator should be capable to grasp the given training. Due to the absence of skill, he will repeat the mistake thus it increases the chance of an accident.

Countermeasure: The operator should be according to process criticality

steel Slitting-burr

steel Slitting-burr

what factors produced BURR in steel slitting?

Identify Cause: Raw material grade & thickness

Reason: Due to die & punch clearance is dependent on raw material thickness. So it is important to feed actual sheet thickness material. If we select a sheet having less thickness from actual then in this condition clearance between die & punch will be more and at the time of cutting proper shearing & breakage will not be produced. Thus burr will be formed. As well if we will use higher sheet thicknesses then less clearance will be maintained or no clearance thus cutting process will be interrupted and heavy accident will go on.

Countermeasure: Proper control on raw material should be taken place by the RI department. Also, quality & production supervisors should be ensuring about the RM before feeding in a tool. For proper implementation of the above idea, this should be converting into a system.

Identify Cause: Part handling

Reason: The method is directly related with Man i.e. operator

resource. In absence of proper handling or part loading method into the tool may cause of burr. Sometimes part trim/edge get damage due to unsafe part handling or movement.

Countermeasure: An operator should be sufficiently trained

 

 

 

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Stainless Steel High Precision Slitting Line

LOTOS SOLUTIONS FOR STEEL SLITTING PROBLEMS:

STEEL SLITTING PROBLEMS include; edge waves, crossbow, knife marks, burrs, camber, and inconsistent slit widths. some of these issues may be creat by poor material quality, but more often caused by disorders which happen in the system during the coil slitting process. LOTOSFORMING discuss slitting problems and present solutions to reduce possible problems.

PROBLEM      /   POSSIBLE CAUSE

What arises Problems during metal slitting?

How to avoid slit-in coil slitting problems?

Many issues can happen in steel slittings such as poor edge quality, edge burr, edge wave, camber, crossbow, knife marks, and slit width.

  • Too much BURR generated from slit process
  1. Too Much side pressure
  2. Wrong main shaft angle
  3. Excessive blade penetration
  4. Dull or incorrectly resharpened blades
  5. Slitter shaft vibration in high speed

Burr is an edge fault that accrues during slitting. The primary cause of burr is a horizontal knife clearance that is very tight or very weak. A wrong clearance spontaneously causes a poor-quality edge. In fact, one of the specifications of a poor-quality edge is a burr.

  • Top knives chipping
  1. Too Much side pressure
  2. Too little blade overlap
  3. Radial runout in the top knife
  4. Top knife jumping out during operation

Extensions to the COIL STEEL SLITTING PROBLEMS :

  • Blade life too short
  1. Blade incorrectly resharpened (burred cutting edges – heavy burrs)
  2. Excessive blade penetration too deep – too shallow
  3. Too much side pressure
  4. Excessive cant angle
  5. Radial runout
  6. Axial runout or wobbling in lower knife

 

  • Ragged edge on ONE side of steel strips
  1. Cant angle much too steep
  2. Blade penetration too deep
  3. Blade cutting angle incorrectly selected and/or sharpened

 

  • Ragged edge on both sides of a cut
  1. Blade angle incorrectly selected
  2. Cant angle much too steep
  3. Blade penetration too deep
  4. Blade cutting angle incorrectly selected and/or sharpened
  5. Incorrect offset
  6. Radial runout
  7. Heavy vibration at high speed

 

PROBLEM THAT OCCURS IN METAL SLITTING?

  • Scallop slit line
  1. Axial runout on a lower knife

 

  • Web folds between blades are not cut
  1. Negative cant angle
  2. Blades improperly reground
  3. Side pressure too light

 

  • Tearing of web  at a cut point
  1. Incorrect trim removal
  2. Blade penetration too deep. Web not truly tangent to the top point of a bottom knife

 

All you need to know about Solve Steel Slitting Problems :

  • Interrupted slitting
  1. Nicked or damaged cutting blades
  2. Radial runout of either top knife or bottom knife or both
  3. Side pressure too light

 

  • Web breaks
  1. Nick on any edge of a knife (usually a top knife)
  2. Web tensions too high
  3. Web not truly tangent
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Advantages of Roll Forming :

Advantages of Roll Forming :

  • One important of advantages of Roll Forming the roll forming process allows operations such as punching, notching, and welding to be performed in-line. Labor cost and time for secondary operations are reduced or eliminated, reducing part costs.
  • Roll form tooling allows for a high degree of flexibility. A single set of roll form tools will make almost any length of the same cross-section. Multiple sets of tools for varying length parts are not required.
  • Roll forming can provide better dimensional control than other competing metal forming processes.
  • Repeatability is inherent in the process, allowing easier assembly of roll-formed parts into your finished product, and minimizing problems due to “standard” tolerance build-up.

Advantages of roll forming relative to extrusion methods:

  • practically all metals can be roll-formed
  • roll forming can eliminate secondary operations multiple-stage operations such as notching, punching, and post-painting.
  • economically features

Roll Forming Line Process

To check the advantages of Roll Forming, we must first understand what is Roll Forming Process? Roll forming steel is essentially a continuous bending operation performed on the metal strip at room temperature. Tandem sets of rolls progressively shape the metal until the desired cross-sectional profile is achieved.

Roll forming is ideal for producing parts with long lengths or in large quantities. It can also produce parts of multiple lengths from the same tooling. Virtually any material that can be formed using sheet forming techniques can also be roll-formed. Roll forming may also be an excellent solution whenever the consistency of the cross-sectional profile is critical.

Benefits of Cold Roll Form Process

Roll forming has benefits & advantages over braking and extruding such as roll forming can produce more parts with more uniformity and stability all over the length of the part. High productivity rate as compared to other manufacturing processes. Able to combine multiple manufacturing operations in-line with the roll forming stations greatly reducing total manufacturing costs

  • Reduces handling, packaging and shipping costs
  • Produces parts of various lengths from the same roll sets
  • Able to produce parts with different hole patterns from the same roll sets
  • Capable of eliminating supplemental operations 
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Roll Forming Machine Basics Parts

How do Roll Forming Machines work?

 

All Roll forming machine in the industry has the same basic design, a roll forming machine includes:

DE COILER: to load raw material coil on that and open coil to a sheet, based on forming speed.

Feeding roller and leveling: after recoiler material should be straightening and leveling before forming to has a better result from forming steps. so we add leveling station in the first part of a machine but mostly is used for more than 1 mm thickness.

Pre-punching and marking: some of the wholes should punch before forming based on design, also upon requirement. we will add marking roller before forming stations.

Forming stations: the number of stations come from our experienced design DPT, based on thickness and shape each drawing need different forming stations number.

Torque head or final guide: in any roll forming machine last station before cutting should be torque head, to modify length twisting and turning to have a final 6-meter length in standard accuracy and shape.

Cutting or saw machine: at the end of forming machine we install the cutting system that’s hydraulic or mechanic saw, and it can be flying to make non-stop cutting. it’s up to forming machine speed and budget requirement.

Electronic cabinet: in developed manufacture such as LOTOS use PLC CONTROL to program and set machine.this is the machine brain for control and manage to punch, cutting, speed, feeding.

In LOTOSFORMING we select match HDMI, DRIVE, PLC, ENCODER with machine electronic motor to reduce PLC error as much as it can.

Roll forming Systems Machine Development:

In 2019 any roll forming manufacturer doesn’t use CAD/CAM design software cannot produce long term performance roll forming machines. roll forming design is one of the difficult machinery in the industry that definitely need CAD/CAM software to analyses and simulation steel with each station before producing. running roll forming machine nowadays most of the manufacture use PLC control to have less tolerance in final products.

So to have developed manufacture for roll forming machine, such as LOTOSFORMING, should have a great design team with enough experience on CAD/CAM software in roller drawing.

Roll Forming Tolerances :

To compare roll forming producing tolerance with old way machinery with shearing and break machines, for sure roll forming accuracy is really much higher than any other way. during the forming station also should care about material reaction and spring back to reduce tolerance,

The advantages of Roll forming Lines Machines  

Except for benefits we explained in previous comments and posts:

  1. Roll forming is energy efficient, cause informing station we won’t use any heating during forming, most of forming machine work in normal room temperature.
  2. Also based on CNC control it also reduces worker in a factory.
  3.  Before we design roller we will calculate input material width to make waste as less as it can.

 

 

 

 

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Roll Forming Process

what is mean Roll Forming Process?

Roll Forming Process is a type of rolling involving the continuous bending of a long strip of sheet metal (typically coiled steel) into the desired cross-section. Roll forming involves uncoiling a long strip of metal and sending it through several stacks of rollers set up in a long line. It performed at room temperature, hence the moniker ‘cold’, which is often dropped. Roll forming at room temperature maintains or even improves the properties of the feedstock material. The strip passes through sets of rolls mounted on consecutive stands. each set performing only an incremental part of the bend until the desired cross-section (profile) obtain. Roll forming is ideal for producing constant-profile parts with long lengths and in large quantities.

Cold Roll Forming Process : 

Cold Roll Forming Process is a bending process where the bending occurs gradually in several forming steps from an undeformed strip to a finished profile in roll forming machine. The process is very interesting for the sheet metal industry due to the high speed in which the profile can produce by a roll forming machine. High strength steel has, in recent years, become more common in cold roll forming. These materials have advantages but also disadvantages that affect the design of the process. The cold roll forming process a highly efficient process use to produce profiles for many applications, for example, vehicles, buildings, and domestic machines, and etc. Therefore, it’s market share is increasing every year. Many of the above products are already today made of high strength steel and the usage of these materials will likely continue to increase.

Metal Cold Forming  :

Cold Roll Forming Process widely use in construction, automobile, railway, aerospace, and other fields. As a kind of common metal skeleton in construction. the forming quality of C-channel steel is particularly important. However, with the shape of forming products becoming more and more complex, the requirement for forming process is becoming higher and higher. In industrial production, technicians also generally design roll flowers by the trial-and-error method. which causes a large number of human and financiallosses.

Cold roll forming is a process of metal slow deformation due to its special forming length. The front part of the sheet always forms faster than that of the back part. In cold roll forming a profile form in several forming steps from an undeformed strip to a finished profile. The forming process complicates due to the fact that. the forming does not only occur in the tools but also between each forming stand. When creating the tools the tool designer must decide how many forming steps the profile demands. The number of steps depending on the shape of the cross-section, tolerance, thickness and material properties. It is important to minimize the number of steps as this reduces the cost of the cold roll forming machine. Then the process can be a competitive alternative also for smaller production volumes. Therefore the knowledge of how high strength steel affects the number of forming steps is important.

Rolled Steel Roll Forming Machine:

Cold Rolled Steel is steel which has been rolled at room temperature, below its recrystallization temperature. This increases its strength and hardness and decreases its ductility. In addition to the improvement of mechanical properties, cold rolling results in more control over the shape and dimensions of the finished product. Cold Rolled steel has an improved surface finish and tighter tolerances compared to hot rolled steel. It commonly uses for parts requiring cold forming, such as crimping, swaging or bending. It can use for Shafts, machinery parts, bolts, and pinions, and gears, as well as in the creation of furniture, appliances and other consumer goods. Cold Rolled Steel can purchase online and at any Metal Supermarkets location. It can be cut to your exact specifications.

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Roll forming

Roll forming

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